Process Economics: Dr. Farrukh Jamil

Process Economics
Course code: ECO302

Replacement and Maintenance Analysis
Dr. Farrukh Jamil
1
– Types of maintenance
– Types of Replacement problem
Reasons for considering the
replacement
• There are two basic reasons for considering
the replacement of an equipment
• Physical impairment of the various parts or
• Obsolescence of the equipment.
• Physical impairment refers only to changes in the
physical condition of the machine itself. This
would lead to a decline in the value of the service
rendered, increased operating cost, increased
maintenance cost or a combination of these.
• Obsolescence is due to improvement of the tools
of production, mainly improvement in technology.
Sometimes, the capacity of existing facilities may
be inadequate to meet the current demand.
U nder such situation, the following alternatives
will be considered.
• Replacement of the existing equipment with a
new one.
• Augmenting the existing one with an a
additional equipment.
TYPES OF MAINTENANCE
• Maintenance activity can be classified into two
types:
• preventive maintenance and
• breakdown maintenance.
• Breakdown maintenance is when the organization
only conducts maintenance on a piece of
equipment when the equipment breaks down.
• Preventive maintenance is when an organization
conducts maintenance activities, including
inspections, to help ensure equipment is
functioning within their expected parameters and
to catch indications of minor issues, so that they
can be addressed before a bigger problem occurs.
is regularly performed on a piece of equipment to
lessen the likelihood of it failing.
• Replacement of assets that deteriorate with time
(Replacement due to gradual failure, or wear and tear
of the components of the machines).
This can be further classified into the following types:
(i) Determination of economic life of an asset.
(ii) Replacement of an existing asset with a new asset.
DETERMINATION OF ECONOMIC LIFE
OF AN ASSET
Any asset will have the following cost components:
• Capital recovery cost (average first cost),
computed from the first cost (purchase price) of
the machine.
• Average operating and maintenance cost (O & M
cost).
• Total cost which is the sum of capital recovery cost
(average first cost) and average maintenance cost.
EXAMPLE 1
• A firm is considering replacement of an equipment, whose
first cost is Rs. 4,000 and the scrap value is negligible at the end of any year.
Based on experience, it was found that the maintenance cost is zero during the first
year and it increases by Rs. 200 every year thereafter.
(a) W hen should the equipment be replaced if i = 0% ?
(b) W hen should the equipment be replaced if i = 12% ?
(a) W hen i = 0% . In this problem,

(i) First cost = Rs. 4,000
(ii) Maintenance cost is Rs. 0 during the first year and it increases by Rs. 200 every year
thereafter.
The steps performed for 12 % interest rate :
EXAMPLE 2
Determine the economic life and annual equivalent total cost of machine B.
REPLACEMENT OF EXISTING ASSET
WITH A NEW ASSET
• In this analysis, the annual equivalent cost of
each alternative should be computed first.
• Then the alternative which has the least
cost should be selected as the best
alternative.
Capital Recovery with Return
Consider the following data of a machine. Let
P = purchase price of the machine,
F = salvage value of the machine at the end of machine life,
n = life of the machine in years, and
i = interest rate, compounded annually
This equation represents the capital recovery with return.

Concept of Challenger and Defender
• If an existing equipment is considered for replacement with a new equipment,
then the existing equipment is known as the defender and the new equipment is
known as challenger.
• Assume that an equipment has been purchased about three years back for Rs.
5,00,000 and it is considered for replacement with a new equipment. The supplier
of the new equipment will take the old one for some money, say, Rs. 3,00,000.
• This should be treated as the present value of the existing

equipment and it should be considered for all further economic analysis. The
purchase value of the existing equipment before three years is now known as sunk
cost, and it should not be considered for further analysis.
EXAMPLE 1
• Two years ago, a machine was purchased at a cost of
Rs. 2,00,000 to be useful for eight years. Its salvage
value at the end of its life is Rs. 25,000. The annual
maintenance cost is Rs. 25,000. The market value of
the present machine is Rs. 1,20,000. N ow, a new
machine to cater to the need of the present machine is
available at Rs. 1,50,000 to be useful for six years. Its
annual maintenance cost is Rs. 14,000. The salvage
value of the new machine is Rs. 20,000. U sing an
interest rate of 12% , find whether it is worth replacing
the present machine with the new machine.
EXAMPLE 2
• A diesel engine was installed 10 years ago at a cost of
Rs. 50,000. It has a present realizable market value of Rs.
15,000. If kept, it can be expected to last five years more,
with operating and maintenance cost of Rs. 14,000 per year
and to have a salvage value of Rs. 8,000 at the end of the
fifth year. This engine can be replaced with an improved
version costing Rs. 65,000 which has an expected life of 20
years. This improved version will have an estimated annual
operating and maintenance cost of Rs. 9,000 and
ultimate salvage value of Rs. 13,000. U sing an interest rate
of 15% , make an annual equivalent cost analysis to
determine whether to keep or replace the old engine.
EXAMPLE 3
• A steel highway bridge must either be reinforced or replaced.
Reinforcement would cost Rs. 6,60,000 and would make the bridge fit for an
additional five years of service. If it is reinforced, it is estimated that its net
salvage value would be Rs. 4,00,000 at the time it is retired from service. The
new prestressed concrete bridge would cost Rs. 15,00,000 and would meet the
foreseeable requirements of the next 40 years. Such a bridge would have no
salvage value. It is estimated that the annual maintenance cost of the reinforced
bridge would exceed that of the concrete bridge by Rs. 96,000. If the bridge is
replaced by a new prestressed concrete bridge, the scrap value of the steel would
exceed the demolition cost by Rs. 4,20,000. Assume that the money costs the
state 10%. What would you recommend?
EXAMPLE 4
• Three years back, a municipality purchased a 10 hp motor for pumping
drinking water. Its useful life was estimated to be 10 years. Due to the fast
development of that locality, the municipality is unable to meet the
current demand for water with the existing motor. The municipality can
cope with the situation either by augmenting an additional 5 hp motor or
replacing the existing 10 hp motor with a new 15 hp motor. The details of
these motors are now tabulated.
EXAMPLE 5
• A machine was purchased two years ago for Rs. 10,000. Its
annual maintenance cost is Rs. 750. Its life is six years and its
salvage value at the end of its life is Rs. 1,000. N ow, a company is
offering a new machine at a cost of Rs. 10,000. Its life is four years
and its salvage value at the end of its life is Rs. 4,000. The annual
maintenance cost of the new machine is Rs. 500. The company
which is supplying the new machine is willing to take the old
machine for Rs. 8,000 if it is replaced by the new machine. Assume
an interest rate of 12% , compounded annually.
(a) Find the comparative use value of the old machine.
(b) Is it advisable to replace the old machine?
The End

Process Economics: Dr. Farrukh Jamil

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Process Economics: Dr. Farrukh Jamil

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Process Economics

Course code: ECO302

Dr. Farrukh Jamil

(a) W hen i = 0% . In this problem,

This equation represents the capital recovery with return.

• This should be treated as the present value of the existing

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